Conformable face mask

Abstract

A face mask comprising an elastic sheet and a filtering web. The elastic sheet defines inner and outer surfaces, and an elongated shape. The elongated shape forms a central portion. A cut-out is formed through a thickness of the elastic sheet at the central portion. The filtering web forms at least one pleat, and is bonded to the outer surface of the elastic sheet along a bondline. The bondline borders a chamber region at least partially established by the filtering web, with the cut-out being fluidly open to the chamber region. When worn, the inner surface is placed against the user's face, and a mouth and a portion of the nose of the user is inserted through the at least one cut-out. In some embodiments, the filtering web forms two vertical pleats that are located at opposite sides of a centerline of the face mask.

What is claimed is: 
     
         1 . A face mask comprising:
 an elastic sheet defining:
 an inner surface, 
 an outer surface, 
 an elongated shape forming a central portion and opposing first and second lateral end portions extending from opposite sides, respectively, of the central portion, 
 a first aperture in the first lateral end portion, 
 a second aperture in the second lateral end portion, 
 at least one cut-out through a thickness of the elastic sheet in the central portion; 
   a filtering web forming at least one pleat, the filtering web being bonded to the outer surface of the elastic sheet along a perimeter bondline;   wherein a chamber region is at least partially established by the filtering web and is bordered by the perimeter bondline;   and further wherein the at least one cut-out is fluidly open to the chamber region.   
     
     
         2 . The face mask of  claim 1 , wherein the face mask is configured to provide a worn state in which the inner surface is placed against the user's face, and a mouth and at least a portion of a nose of the user are inserted through the at least one cut-out. 
     
     
         3 . The face mask of  claim 2 , wherein the face mask is configured to form a substantially continuous line of contact with a user's face in the worn state that circumscribes the chamber region. 
     
     
         4 . The face mask of  claim 1 , wherein the elongated shape of the elastic sheet in a flattened state defines a transverse direction generally extending between the first and second apertures, and a longitudinal direction perpendicular to the transverse direction, and further wherein the at least one pleat includes a first vertical pleat having a fold line substantially parallel to the longitudinal direction. 
     
     
         5 . The face mask of  claim 4 , wherein the fold line runs continuously from a first location at the perimeter bondline to a second location on the perimeter bondline opposite the first location. 
     
     
         6 . The face mask of  claim 4 , wherein the at least one pleat includes a second vertical pleat having a fold line substantially parallel to the longitudinal direction. 
     
     
         7 . The face mask of  claim 6 , wherein the elongated shape defines a centerline in the longitudinal direction and bi-secting the central portion, and further wherein the first and second vertical pleats are located at opposite sides of the centerline. 
     
     
         8 . The face mask of  claim 6 , wherein the first and second vertical pleats are configured to cause the elastic sheet to comply with contours of a user's nose root region in the worn state. 
     
     
         9 . The face mask of  claim 1 , wherein the elongated shape of the elastic sheet in a flattened state defines a transverse direction generally extending between the first and second apertures, and a longitudinal direction perpendicular to the transverse direction, and further wherein the at least one pleat includes a horizontal pleat having a fold line substantially parallel to the transverse direction. 
     
     
         10 . The face mask of  claim 9 , wherein the at least one pleat includes a second horizontal pleat having a fold line substantially parallel to the transverse direction. 
     
     
         11 . The face mask of  claim 9 , wherein the at least one pleat includes a first vertical pleat having a fold line substantially parallel to the longitudinal direction. 
     
     
         12 . The face mask of  claim 1 , wherein the elongated shape of the elastic sheet in a flattened state defines a transverse direction generally extending between the first and second apertures, a longitudinal direction perpendicular to the transverse direction, and a centerline in the vertical longitudinal and bi-secting the central portion, and further wherein an edge of the face mask tapers in height from the centerline toward the first and second lateral end portions. 
     
     
         13 . The face mask of  claim 1 , wherein the elastic sheet includes an elastic nonwoven web. 
     
     
         14 . The face mask of  claim 3 , wherein the elastic sheet further includes a polymeric film laminated to the elastic nonwoven web, and further wherein the filtering web is bonded to the polymeric film. 
     
     
         15 . The face mask of  claim 1 , wherein the filtering web includes a filtering layer and a polymeric film layer, and further wherein the polymeric film layer faces the outer surface of the elastic sheet. 
     
     
         16 . The face mask of  claim 1 , wherein the at least one cut-out is an oblong shape. 
     
     
         17 . The face mask of  claim 1 , wherein the at least one cut-out includes a plurality of slits. 
     
     
         18 . The face mask of  claim 17 , wherein the plurality of slits includes first and second slits forming an X shape. 
     
     
         19 . The face mask of  claim 1 , wherein at least one of the elastic sheet and the filtering web forms a flap configured to be folded toward the inner surface and contact a user's face. 
     
     
         20 . A method of using a face mask, the method comprising:
 receiving a face mask including:
 an elastic sheet defining:
 an inner surface, 
 an outer surface, 
 an elongated shape forming a central portion and opposing first and second lateral end portions extending from opposite sides, respectively, of the central portion, 
 a first aperture in the first lateral end portion, 
 a second aperture in the second lateral end portion, 
 at least one cut-out through a thickness of the elastic sheet in the central portion, 
 
 a filtering web forming at least one pleat, the filtering web being bonded to the outer surface of the elastic sheet along a perimeter bondline, 
 wherein a chamber region is at least partially established by the filtering web and is bordered by the perimeter bondline, 
 and further wherein the at least one cut-out is fluidly open to the chamber region; 
   fastening the face mask to a user's head, including:
 placing the first and second apertures over ears of the user, respectively, 
 inserting a mouth and nose region of the user's head through the cut-out, 
 forming a substantially continuous line of contact between a face of the user and the inner surface, the line of contact circumscribing the chamber region; and 
   expanding the at least one pleat in response to an exhaled breath of the user.   
     
     
         21 . A method of  claim 20 , wherein the step of fastening the face mask further includes a region of the inner surface conforming to a shape of a user's face in a vicinity of the user's nose root.